Manufacture of shoes

ABSTRACT

In a method of making shoes having a composite insole which includes a base, a padded liner and a cover, the improvement wherein a plurality of lugs are formed in the cover member for connection to the shoe upper. The lugs are formed so that they are free to bend outwardly from the base member when the edges of the base member are bound by the cover member. This is achieved by forming the lugs so that they are inwardly directed with respect to the side edges of the base member. The present invention also provides an improved base member of the type described above.

v [111 3,841,003 [451 Oct. 15, 1974 MANUFACTURE OF SHOES [75] Inventor: John Huyge, Burlington, Ontario,

Canada [73] Assignee: Susan Shoe Industries Limited,

Ontario, Canada 22 Filed: Apr. 8, 1974 21 Appl. No.: 458,977

[51] Int. Cl. A43b 3/12, A43d 9/00 [58] Field of Search 36/115, 43, 44; 12/142 R, 12/142 S [56] References Cited UNITED STATES PATENTS 2,588,061 3/1952 Vesely 36/11.5 2,773,317 12/1956 Helle 36/115 3,785,070 l/1974 Stafford 36/115 Primary ExaminerPatrick D. Lawson Attorney, Agent, or Firm-Fetherstonhaugh & Co.

[5 7 ABSTRACT In a method of making shoes having a composite insole which includes a base, a padded liner and a cover, the improvement wherein a plurality of lugs are formed in the cover member for connection to the shoe upper. The lugs are formed so that they are free to bend outwardly from the base member when the edges of the base member are bound by the cover member. This is achieved by forming the lugs so that they are inwardly directed with respect to the side edges of the base member. The present invention also provides an improved base member of the type described above.

10 Claims, 3 Drawing Figures MANUFACTURE OF SHOES This invention relates to the manufacture of shoes. In particular, this invention relates to an improved method of manufacturing a sandal and the sandal produced by the improved method.

In the manufacture of shoes such as sandals, it is common practice to secure the upper by locating it in a position between the insole and the sole. When the insole is not a padded insole, the upper may be stitched or otherwise secured to theunderside of the insole without adversely affecting the feel of the sandal when it is worn. However, if the insole is a composite insole including a base member, a resilient pad and a cover, difficulty is experienced in effectively securing the upper member with respect to the insole member without adversely affecting the characteristics of the padded insole if, for example, the upper is secured to the insole by stapling. The portions of the staple which extend through the base member must also extend through the pad member and the cover to be effective as a securing device. The rigid staple would, however, be very uncomfortable to the wearer in view of the fact that it would provide a rigid interruption in an otherwise softly padded surface.

' The present invention overcomes the difficulties of the prior art and provides a simple and efficient method for securing the upper of a sandal or the like to the base member of a padded insole. The present invention also provides an improved sandal construction wherein the upper is secured to the base member of the insole without requiring the securing means to penetrate the pad or liner.

According to an embodiment of the present invention, there is provided an improved method for manufacturing a shoe such as a sandal having an upper member, a sole member and a composite insole including a base member, a liner pad member and a cover member, each having side edges, comprising the steps of forming the base member to provide a plurality of lug members projecting inwardly from side edges thereof, the lug members being outwardly foldable from the plane of the base member, securing the liner pad member and the cover member in an operative position on the base member, folding the lug members outwardly from the plane of the base member and securing the upper member to the lug members to secure the upper member to the composite insole, and thereafter folding the lug members inwardly to the plane of the base member and securing the sole member to the insole member and the upper.

According to a further embodiment of the present invention there is provided an improved shoe having an upper member, a sole member and a composite insole including a base member, a liner pad member and a cover member, each having side edges, the base member being formed to provide a plurality of lug members projecting inwardly from the side edges thereof, said lug members being outwardly foldable from the plane of said base member, said liner pad member and said cover member being secured in an operative position on said base, said upper member being secured to the underside of said base member by securing through said lug members and said sole member being secured tosaid insole member.

The invention will be more clearly understood after reference to the following detailed specification read in conjunction with the drawings, wherein:

FIG. 1 is an exploded pictorial view of a shoe according to an embodiment ofthe present invention;

FIG. 2 is a pictorial view of the underside of the insole of a shoe according to an embodiment of the present invention illustrating the manner in which the upper is secured theretoj and FIG. 3 is a sectional view of an assembled shoe taken in the direction of the arrows 33 of FIG. 2.

With reference to the drawings, it will be seen that the shoe or sandal 10 comprises an upper 12, an insole cover member 14, a resilient liner pad 16, a base member 18 and a sole 20.

The base member 18 may be made from any of the conventional materials and is distinguished from conventional base members by the provision of lug members 22 which are formed by cutting through the thickness of the base member. The lug members 22 project inwardly from adjacent the side edges of the base member so as to be foldable outwardly from the plane of the base member in the manner illustrated in FIG. 2 of the drawings. The lug members must be inwardly projecting with respect to the base member to permit them to fold upwardly relative to the base member when the pad 16 and cover 14 are secured in an operative position as shown in FIG. 2 of the drawings, wherein the marginal edges of the cover member 14 extend over the side edges of the base member and preferably the side edges of the lug members terminate at about oneeighth to one-quarter of an inch from the side edge of the base member.

To assemble the sandal, the liner pad 16 is located in the position overlying the upper surface of the base member 18 and the cover member 14 is located in the position overlying the liner pad 16. The marginal edges of the cover member 14 are folded over the edges of the pad 16 and base member 18 to the position underlying the lower surface of the base member 18 as shown in FIG. 2 of the drawings. The marginal edges of the cover member 14 are secured to the underside of the base member 18 by means of a suitable adhesive or the like. The lug members 22 are then folded outwardly from the plane of the base member as shown in FIG. 2 of the drawings and the lower edges of the upper member are then secured to the lug members 22 by means of staples 24 or the like. It will be noted that even if the staples 24 pass right through the thickness of the lug members 22, they will not pass through the liner pad 16 or the cover 14. As shown in FIG. 3 of the drawings, the thickness of the liner pad 16 is sufficient to accommodate the ridges formed by the staples without causing any discomfort to the wearer. After the upper has been secured to the insole member, the sole 20 is secured in the conventional manner to the underside of the insole member to provide the construction illustrated in FIG. 3 of the drawings wherein the marginal edges of the upper 12 and cover member 14 are located in the position between the insole member and the sole member.

Various modifications of the present invention will be apparent to those skilled in the art without departing from the scope of the invention.

For example, it will be apparent that the upper member may be secured to the lug members 22 by securing means other than staples. In certain instances, it may be desirable to substitute a stitching operation for the stapling operation. Furthermore, if the upper member and the base member are formed from a thermoplastic material, the connection at the lug members may be achieved by thermally bonding the materials to one another.

What I claim as my invention is:

1. A method of manufacturing a shoe having an upper member, a sole member and a composite insole including a base member, a liner pad member and a cover member, each having side edges, comprising the steps of:

a. forming said base member to provide a plurality of lug members projecting inwardly from said side edges of said base member, said lug members being outwardly foldable from the plane of said base member,

b. securing said liner pad member and said cover in an operative position on said base member,

c. folding said lug members outwardly from the plane of said base member and securing said upper member to said lug members to secure said upper member to said composite insole, and

d. securing said sole member to said insole and upper.

2. A method as claimed in claim 1 wherein said lug members are formed by cutting through the complete thickness of said member.

3. A method as claimed in claim 2 wherein said upper member is secured to said lug members by securing means which pass the complete thickness of said lug members.

4. A method as claimed in claim 3 wherein said securing means is in the form of metal staples.

5. A method as claimed in claim 1 wherein at least six lugs are formed in the base member, the lugs being arranged three adjacent either side edge of the base.

6. A method as claimed in claim 1 wherein the lugs are formed with side edges terminating at about 0. to 0.25 inches from an adjacent side edge of the base member.

7. A base member for use in the manufacture of shoes having an upper member, a sole member and a composite insole member including a base member, a liner pad member and a cover member, said base member comprising a main body having side edges conforming to the shape of the sole of the shoe and a plurality of lug members projecting inwardly from the side edges thereof, said lug members being outwardly foldable from the plane of said base member.

8. A base member as claimed in claim 7 wherein said lug members are formed by cutting through the complete thickness of said base member.

9. A base member as claimed in claim 8 wherein said lug members are formed with side edges terminating at about 0.125 to 0.25 inches from an adjacent side edge of the base member.

10. A sandal comprising an upper member, a sole member and a composite insole including a base member, a liner pad member and a cover member, each having side edges, said base member being formed with a plurality of lug members projecting inwardly from the side edges thereof, said lug members being outwardly foldable from the plane of said base member, said liner pad and said cover being secured to said base member in a position extending over the upper surface of said base member, said upper member being secured to said lug members by means of securing means which penetrate said lug members and said sole member being secured to said base member in a position overlying the portions of the upper member which are secured to the lug members. 

1. A method of manufacturing A shoe having an upper member, a sole member and a composite insole including a base member, a liner pad member and a cover member, each having side edges, comprising the steps of: a. forming said base member to provide a plurality of lug members projecting inwardly from said side edges of said base member, said lug members being outwardly foldable from the plane of said base member, b. securing said liner pad member and said cover in an operative position on said base member, c. folding said lug members outwardly from the plane of said base member and securing said upper member to said lug members to secure said upper member to said composite insole, and d. securing said sole member to said insole and upper.
 2. A method as claimed in claim 1 wherein said lug members are formed by cutting through the complete thickness of said member.
 3. A method as claimed in claim 2 wherein said upper member is secured to said lug members by securing means which pass the complete thickness of said lug members.
 4. A method as claimed in claim 3 wherein said securing means is in the form of metal staples.
 5. A method as claimed in claim 1 wherein at least six lugs are formed in the base member, the lugs being arranged three adjacent either side edge of the base.
 6. A method as claimed in claim 1 wherein the lugs are formed with side edges terminating at about 0.125 to 0.25 inches from an adjacent side edge of the base member.
 7. A base member for use in the manufacture of shoes having an upper member, a sole member and a composite insole member including a base member, a liner pad member and a cover member, said base member comprising a main body having side edges conforming to the shape of the sole of the shoe and a plurality of lug members projecting inwardly from the side edges thereof, said lug members being outwardly foldable from the plane of said base member.
 8. A base member as claimed in claim 7 wherein said lug members are formed by cutting through the complete thickness of said base member.
 9. A base member as claimed in claim 8 wherein said lug members are formed with side edges terminating at about 0.125 to 0.25 inches from an adjacent side edge of the base member.
 10. A sandal comprising an upper member, a sole member and a composite insole including a base member, a liner pad member and a cover member, each having side edges, said base member being formed with a plurality of lug members projecting inwardly from the side edges thereof, said lug members being outwardly foldable from the plane of said base member, said liner pad and said cover being secured to said base member in a position extending over the upper surface of said base member, said upper member being secured to said lug members by means of securing means which penetrate said lug members and said sole member being secured to said base member in a position overlying the portions of the upper member which are secured to the lug members. 